Section – III : Installation : (A) Earthing & Earth

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V O L U M E – VIII

S E C T I O N - III :: I N S TA L LAT I O N
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(A) E A R T H I N G & E A R T H M A T
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SECTION - INSTALLATION
Section – III : Installation : (A) Earthing & Earth

SUB-SECTION - A

EARTHING & EARTH MAT

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CLAUSE NO. CONTENTS PAGE NO.
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1.0 Scope 11

2.0 Standards 12

3.0 Details of Earthing system 12

4.0 Design consideration 13

5.0 Earthing Mat 14

6.0 Installation 15

7.0 Equipment & Structural Earthing 16

8.0 Jointing 17

9.0 Power cable earthing 18

10.0 Specific requirement for earthing 18

systems

11.0 Lightning protection 18

12.0 Tests 19

13.0 Tender document 19

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Section – III : Installation : (A) Earthing & Earth

SUB-SECTION - A
EARTHING & EARTH MAT

1.0 SCOPE:

This Sub-section covers design, supply, storage, fabrication; transportation to site,

installation and testing of earth mat and effective associated grounding system for the
400kV/220kV Sub-station. Exact layout and location of earthing conductors, earth
electrodes, earth pits and earthing pit connections shall be designed to suit the site
conditions.

1.1 Neutral points of systems of different voltages, metallic enclosures and frame works associated
with all current carrying equipments and extraneous metal works associated with electric
system shall be connected to a single earthing system unless stipulated otherwise.

1.2 The Contractor's scope includes

a) Design of Earthing system duly measuring Soil resistivity, earthing system calculations,
safe touch, step potentials calculations as per standards. All works such as cutting,
bending, supporting, welding, soldering, coating, drilling, brazing, clamping, bolting, and
connecting on to structures, pipes, equipment frames, terminals, rails or other devices
treating the joints with appropriate paint.

b) Installation of earthing conductor for the main earthing mat/grid comprising of 40 mm

MS round for the outdoor switchyard area. These shall be buried in ground at a depth of
600 mm. The unit rate for the work shall include excavation and backfilling per cubic
meter, laying the conductor, brazing the joints, and providing the risers, wherever
necessary and others required to make earth mat fully operational.

c) Installation of earth riser connection leads to the equipments and risers on steel structures
including equipment framework and other non-current carrying parts in the switchyard
and transformer yard and all extraneous metallic framework not associated with
equipment, walls etc. The unit rate shall include putting the riser conductor in position,
cleating and clamping at regular intervals, welding / brazing of risers/leads as required to
the main earth grid and providing bolting joints at the equipment earthing terminals and
test pits.

d) Installation of earthing rod / pipe / electrodes contractor’s unit rate shall include
installation of these rods / pipes in earth pits both for treated and untreated, providing
connection to the main earthing grid, excavation and back-filling of earthing pits with all
material as required including cover placing the pipe in position, for treated earth pit and
connecting to main earth grid conductors.

e) Tentative quantities for the earthing conductor, conductor above ground connecting to
structures, columns etc., earthing leads all along the cable trenches, untreated and treated
earth pits are given in the price schedule. Bidder shall quote for the same but they shall
note that they have to design earthing system and provide the same at the unit prices
quoted by them. Bidder shall do the earthing of all the motors coming in the switchyard
area with in quoted prices.
Section – III : Installation : (A) Earthing & Earth

f) Connecting switchyard fencing to the earth mat and extending the earthmat one meter
beyond fence is to be done by the bidder.

g) The material like earthing conductor, earth electrodes/pipes, accessories and fittings such
as bolts, washers, nuts, screws, cleats, clamps, anchors, fasteners etc. shall be supplied by
the bidder.

h) The design calculations for earthing system, calculation of BOM of earthing conductor,
raisers, electrodes etc. which shall be submitted for prior approval before execution.

2.0 STANDARDS:
Earthing system installation shall be in strict accordance with the latest editions of Indian
Electricity Rules, relevant Indian Standards and Codes of practice and Regulations existing
in the locality where the system is installed.

i) Code of practice for Earthing IS: 3043

ii) Code of practice for the protection of Building and allied
structures against lightning IS:2309
iii) Indian Electricity Rules 1956 with latest amendments.
iv) National Electricity Safety code IEEE-80.
v) Specification for structural steel IS-2062
vi) Method of testing or uniformity of coating zinc IS: 2633
vii) Specification for hot dip zinc coating IS: 4759.

3.0 DETAILS OF EARTHING SYSTEM:

Item Size Material

i) Main Earthing Conductor 40 mm dia rod Mild Steel

ii) Conductor above ground level 75x12 mm Flat Galvanised Steel

and earthing leads for equipment
structures, columns and other
auxiliary structures buildings.

iii) Earthing leads for cable trenches. 50 x 8mm G. S Flat

iv) Rod Electrode 40 mm dia Mild Steel 3000 mm long Rod

v) Riser below ground connecting 40mm dia MS rod.

Earth Mat to above ground level
Earthing GS flat

vi) Earthing of Indoor LT panels and 50 x 8 mm G.S.Flat

outdoor Marshalling boxes, MOM
Boxes, Junction Boxes & Lighting
Panels, cable trays & cables.
Section – III : Installation : (A) Earthing & Earth

vii) CI pipe electrode Pipe back filled 2.75 mtrs. CI pipe electrode
treated with BH coke mixed with 125 mm dia.
salt (in treated earth pit)

viii) Earthing for Motors 25 x 3 mm flat Galvanised Steel

Connections from mat to the switchyard and transformer yard equipment; framework and
other earthing points shall be made.

4.0 DESIGN CONSIDERATION:

4.1 The design of the earthing mat shall be based on the following:

4.1.1 Average soil resistivity: As per soil test results to be determined

(Ohm-metre) prior to submission of designs by the contractor

4.1.2 Magnitude of design fault

current : 50.0 (KA)

4.1.3 Duration of fault (Second): One (1)

4.1.4 Duration of shock (Second): Half (0.5)

4.1.5 Material of earthing mat: Mild Steel conductor

4.1.6 Type of joints

a) Permanent: Welded
b) Suitable for testing operations: Bolted

4.1.7 Values of maximum allowable

Temperature in

a) Welded joints (deg.C): 620

b) Bolted joints (deg. C): 310

4.1.8 Value of design ambient temperature: As per project site data

4.1.9 Type of surface layer: Crushed rock of size 15-20 mm

4.1.10 Average resistivity of 3000

surface layer (Ohm-meter):

4.1.11 Thickness of surface layer: 150 mm

4.1.12 Minimum size and type of

earthing mat conductor
a) Size: Mild Steel 40 mm dia
b) Type: Rod
4.1.13 Allowance for corrosiveness : To be considered in design according to type of soil.
Section – III : Installation : (A) Earthing & Earth

4.2 The design of the earthing mat shall be such that the safe values of touch, step and
transferred potential are not exceeded under any condition. The combined resistance of
earth grid including rods in the station shall not exceed 1.0 Ω (maximum). Earth electrodes
shall be provided as required and connected to earth mat to achieve the desired value.

4.3 If the transferred potential exceeds the permissible value, the contractor shall take necessary
proven measures to protect the affected systems from the effects of transferred potential to
the satisfaction of the Owner.

4.4 All conductors buried in earth and concrete shall be mild steel. All conductors above ground
level and earthing leads shall be galvanised steel.

4.5 After the completion of earth mat, the earth resistivity may be measured. In case the earth
resistance is more than one ohm, earth mat may be extended extra electrodes installed or
other appropriate steps must be taken so that the earth resistance is less than one ohm, at no
extra cost to the Purchaser.

4.6 The bidder himself shall fully satisfy himself about the nature of the soil and earth resistivity
by two-layer method measurement prior to the submission of bid. Any variation in the data
furnished in the bidding documents including value of earth resistance shall not constitute a
valid reason in affecting the terms and conditions of the tender including price to be paid.
Bidder shall furnish detailed design calculations along with soft ware for the design and
drawings with bill of material including soft copy for the same.

5.0 EARTHING MAT:

5.1 Earthing conductors in outdoor areas shall be buried at least 600 mm below finished ground
level unless stated other wise. Wherever essential, these shall have to be buried at larger
depths to restrict potentials within permissible values. Unit rate quoted for laying shall be
applicable for larger depths also.

5.3 Wherever earthing conductors cross cable trenches, underground service ducts, pipes,
tunnels, railway tracks etc., it shall be laid minimum 300 mm below them and shall be
re-routed in case it fouls with equipment/structure foundations.

5.4 Tap-connection from the earthing grid to the equipment/structure to be earthed shall be
terminated on the earthing terminals of the equipment/structure, if the equipment is available
at the time of laying the grid. Otherwise, "earth insert” with temporary "earth riser" shall be
provided near the equipment foundation/pedestal or location decided by the purchaser for
future connections to the equipment earthing terminals.

5.5 Earthing conductors along their run in cable trench, cable ladders, walls, etc. Shall be supported
by suitable welding/cleating at intervals of 750 mm. Earthing conductors along cable
trenches shall be on the wall nearer to the equipment. Wherever it passes through walls,
floors, etc., galvanised iron sleeves shall be provided for the passage of the conductor. Both
ends of sleeve shall be sealed to prevent the passage of water through the sleeves.

5.6 Earthing conductor around the building in addition to earthmat below the building shall be
buried in earth at a minimum distance of 1500 mm from the outer boundary of the building.
Section – III : Installation : (A) Earthing & Earth

In case high temperature is encountered at some location, the earthing conductor shall be laid
minimum 1500 mm away from such location. Reinforcement provided in the building shall
also be connected to earthmat. The area of reinforcements shall not be considered
contributing to the earthmat design requirement.

5.7 In outdoor areas, tap connections shall be brought 450 mm above ground level for making
connections in future, if equipment is not available at the time of installations.

5.8 Earthing conductors crossing the road shall be installed/laid at greater depth to suit the site
conditions without any extra cost to the Purchaser.

5.9 Earthing conductors embedded in the concrete shall have approximately 50 mm concrete
cover.

5.10 If the earthing mat extends right up to fencing the design calculations reveal that the values
of touch potentials both from within and outside the fenced-in area are within safe limits,
fencing shall be connected with the earthing mat at frequent intervals.

5.11 If the earthing mat extends right up to the fencing, but the calculations reveal that touch
potential at the fence is beyond tolerable limits, the earthing mat shall be terminated about
1.5 meter within the boundary line of the fence and the fence shall be electrically isolated and
independently earthed by running earthing conductor underneath the fence and bounded with
the fence at frequent intervals or by means of adequate number of earthing electrodes.

6.0 INSTALLATION

i) The CONTRACTOR shall install earthing conductor required for the system
and individual equipment earthing. The contractor shall also carryout the excavation
and trenching and civil work involved in connection with laying earth mat, earth pits
etc. The contractor shall be responsible for maintaining excavation, bracing, shoring,
pumping and disposal of water without damage to the property. The contractor shall
also back-fill and reinstate the trenches after installation of the earth conductors.

ii) Back-fill material to be placed over buried earth conductor shall be free from stones
and other harmful mixtures. Back-fill material shall be placed in layers of 150 mm,
uniformly spread along the ditch, and tempered utilizing pneumatic tampers or other
approved means. Planks or other protections shall be placed over conductors in
hazardous areas after layer of earth has been placed over the conductor, but before
placement of balance of back fill. If the excavated soil is found unsuitable for back
filling, the CONTRACTOR shall arrange for suitable soil from outside without any
expense to the OWNER.

iii) The Contractor shall co-ordinate with civil construction and shall install the earthing
wires before the commencement of concrete work.

iv) The welding equipments and all consumable items such as welding rods etc. required
for installation of the earthing system shall be arranged by the Contractor and related
cost is deemed to have been included in the bid price.

7.0 EQUIPMENT & STRUCTURAL EARTHING

Section – III : Installation : (A) Earthing & Earth

7.1 Earthing pads/terminals shall be provided by the Supplier of the apparatus/equipment at

accessible position. The connection between earthing pads and the earthing grid shall be
made by short and direct earthing leads free from kinks and splices. In case earthing
pads/terminals are not provided on the item to be earthed, same shall be provided by the
contractor at no extra cost to the purchaser. Neutral connection shall never be used for the
equipment earthing.

7.2 Whether specifically shown in drawings or not, Steel/RCC columns, metallic stairs etc. shall
be connected to the nearby earthing grid conductor by two earthing leads. Electrical
continuity shall be ensured by bonding different sections of hand-rails and metallic stairs.

7.3 Metallic pipes; conduits and cable tray sections for cable installation shall be bonded to
ensure electrical continuity and connected to earthing conductors at regular interval. Apart
from intermediate connections, beginning and end points shall also be connected to earthing
system.

7.4 Metallic conduits shall not be used as earth continuity conductor.

7.5.1 A separate earthing conductor shall be provided for earthing lighting fixtures, receptacles,
switches, junction boxes, lighting conduits etc.

7.6 Wherever earthing conductor crosses or runs along metallic structures such as gas, water,
steam conduits, etc. And steel reinforcement in concrete it shall be bonded to the same.

7.7 Light poles, junction boxes on the poles, cable and cable boxes/glands, lockout switches etc.
shall be connected to the earthing conductor running along with the supply cable which in
turn shall be connected to earthing grid conductor at a minimum two points whether
specifically shown or not.

7.8 Railway tracks within switchyard area shall be bonded across fishplates and connected to
earthing grid at several locations. At the point where track leaves the plant substation area,
the rail section shall be provided with insulated joint at both ends.

7.9 Every alternate post of the fence and gates shall be connected to earthing loop by one lead.

7.10.1 Flexible earthing connectors shall be provided where flexible conduits are connected to rigid
conduits to ensure continuity.

7.10.2 Metallic frames of all electrical equipments shall be earthed by two separate and distinct
connections with earthing system.

7.10.3 Shield wire in substations shall be connected to the earthing grid at every alternate
switchyard gantry tower.
7.13 Earthing of portable tools, appliances and welding equipment shall conform to the code of
practice for earthing, IS: 3043.

7.14 A separate earth electrode (Rod of 3.0m) shall be provided adjacent to structures supporting
lightning arrester and coupling capacitors. Earth connections shall be as short and as straight
as practicable. For lightning arresters and lighting down conductors and CVT connected to
main mat at least at two points at a depth of 600mm below ground mounted near
Section – III : Installation : (A) Earthing & Earth

transformer, earth conductors shall be located near the tank and collar.

7.15 The risers taken along the main switchyard structures and equipment structures (up to their
top) shall be clamped to the structures at an interval of not more than one meter.

8.0 JOINTING

8.1 Earthing connections with equipment earthing pads and at treated / untreated pits shall be bolted
type. Contact surfaces shall be free from scale, paint, enamel, grease, rust or dirt. Two bolts
shall be provided for making each connection. Equipment bolted connection, after being
checked and tested, shall be painted with anti corrosive paint/compound.

8.2 The design of earthing mat shall provide for welded joints between the earthing mat conductors,
except where the mat may have to be isolated from equipment, cable sheath, test pits, etc.
for testing. The joints intended to be isolated for testing shall be bolted. Connection
between equipment earthing lead and main earthing conductors and between main earthing
conductors shall be welded/brazed type.

8.3 The welds shall be treated with Barium Chromate to protect them from rusting. The
exposed steel conductors/risers shall be protected with bituminous paint. The Barium
Chromate treated surfaces shall thereafter be painted with red lead and aluminum paint and
coated with bituminous paint.

8.4 Steel to copper connections shall be brazed type and shall be treated to prevent moisture
ingression.

8.5 Resistance of the joint shall not be more than the resistance of the equivalent length of the
conductor.

8.6 All ground connections shall be made by electric arc welding. All welded joints shall be
allowed to cool down gradually to atmospheric temperature before putting any load on it.
Artificial cooling shall not be allowed.

8.7 Bending of large diameter rod/thick conductor shall be done preferably by gas heating.

8.8 Provisions shall be made for thermal expansion of the steel flats by giving smooth circular
bends. Bending shall not cause any fatigue in the material of bends. Drawings to this effect
must be enclosed to the bid.

8.9 All arc welding with large dia conductors shall be done with low hydrogen content
electrodes.

9.0 POWER CABLE EARTHING

Metallic sheaths and armour of all multi core power cables shall be earthed at both
equipment and switchgear ends as per IS: 1255. Sheath and armour of single core power
cables shall be earthed at switchgear end only.

10.0 SPECIFIC REQUIREMENT FOR EARTHING SYSTEMS

10.1 Each earthing lead from the neutral of the power transformer shall be directly connected to
Section – III : Installation : (A) Earthing & Earth

pipe electrodes of treated earth pits which, in turn, shall be connected to station earthing
grid. All pipe electrodes shall have cement concrete pit with a Cast Iron cover hinged to a
cast iron frame to have an access to the joints.

10.2 Earthing mat of size 900 x 900 mm comprising of closely spaced (300x300mm) conductors
shall be provided at 300 mm below ground under the operating handles of the isolators
further, and connected to the main mat atleast at two points. Operating handle of isolator
shall be bonded together by a flexible connection. MOM boxes both for main and earth
switch shall be directly connected to the earthing mat.

10.3 Galvanised Steel:

a) Steel conductors above ground level shall be galvanised according to IS: 2629.
b) The minimum weight of the zinc coating shall be 900 gm/sq.m.
c) The galvanised surfaces shall consist of a continuous and uniformly thick coating of
zinc, firmly adhering to the surfaces of steel. The finished surface shall be clean and
smooth and shall be free from defects like discoloured patches, bare spots, unevenness of
coating, smelter which is loosely attached to the steel globules, spiky deposits, blistered
surfaces, flaking or peeling off etc. The presence of any of these defects noticed on
visual or microscopic inspection shall render the material liable to rejection.

10.4 Each transformer shall be provided with 3 nos treated earth pits near to them for earthing (as
per the standard practice). Cast iron pipes 125 mm in dia and 2.75 meters long and 12.7 mm
thick shall be buried vertically in the pits and finally broken coke and salt shall be filled at
least 150 mm around the pipe for the entire depth. These earth pits in turn shall be
connected to the earth mat. Circular R.C.C. Collar with diameter of 1 meter and height of
65cm with suitable thickness and RCC cover shall also be provided for each treated pit. The
cost quoted for earth pit includes supply of all materials includes coke and salt.

11.0 LIGHTNING PROTECTION

11.1 Direct Stroke lightning Protection (DSLP) shall be provided in the EHV switchyard
by Lightning Masts and Shield wires.
11.2 Conductors of the lightning protection system shall not be connected with the
conductors of the safety earthing system above ground level.
11.3 Down conductors shall be cleated on the structures at 750 mm interval.
11.4 A 40 mm dia, 3000 mm long MS Earth Electrode shall be provided with lightning
masts. Connection between each down conductor and rod electrodes shall be made
via test joint located approximately 1500 mm above ground level.
11.5 Lightning conductors shall not pass through or run inside G.I. conduits.

11.6 All metallic structures within a vicinity of 2000 mm in air and 5000 mm below ground shall
be bounded to the conductors of lightning protection system.

11.7 Lightning protection system installation shall be in strict accordance with the latest editions
of Indian Electricity Rules, Indian Standards and Codes of Practice and Regulations existing
in the locality where the system is installed.

12.0 TESTS
Section – III : Installation : (A) Earthing & Earth

12.1 Tests shall be carried out by the successful bidder to determine the as built resistance of the
earthing mat laid as per the design approved by the Owner. Field measurements of step and
touch potentials shall also be carried out by the successful tendered to show that the design
and installation of the earthing mat are adequate. The results of the test/ measurements shall
be furnished to the Owner. If the values of these parameters are found to exceed the
permissible values, the contractor shall take necessary remedial measures to bring the values
of these quantities within the tolerable limits at no extra cost to the Purchaser. Continuity of
all conductors and efficiency of all bonds and joints shall be tested. All the equipment
necessary for the test shall be arranged by the contractor at no extra cost to Purchaser.

13.0 DOCUMENTS TO BE SUBMITTED :

The successful tenderer shall furnish the following: -

i) The tenderer shall submit a description of the design procedure along with the various
equations and values of constants he intends to adopt for the design. Detailed design
calculations for the earthing mat, estimated resistance of the earthing mat, values of
estimated step, touch and transferred potentials, ground potential rise etc.

ii) The tenderer shall also submit diagrams of the proposed connection arrangements with
equipment frame-work, earthing electrodes, lightning arresters, capacitor voltage
transformers, and voltage transformer, and details of welded and bolted joints.

iii) Description of the proposed measures for limiting the transferred potential in the systems
under influence.

iv) Description of methods for measurement of earthing mat resistance, touch and step
potentials after laying the earthing mat.

v) Drawing showing the layout of earthing mat and the system of risers and connections to
the various earthing points. Drawing for treated and untreated earth pits and composition
details of coke, salt mixture used for filling.

vi) Estimated quantity of earthing mat conductor, risers, connecting strips and their sizes.

vii) Drawings of welding joints adopted in the laying of earth mat. The size of welding fillet
and supporting calculations in support of its suitability to carry the short circuit current
shall also be furnished.